Airec Compact 25 Installation and Maintenance Manual
- Type
- Installation and Maintenance Manual
Installation and maintenance manual
Product family Compact
Version: 002
Date: 31-08-2018
General information
The Airec Compact exchanger is an asymmetric brazed plate heat
exchanger consisting of stainless steel plates brazed together with
copper or nickel. The Compact family consist of six different mod-
els, Compact 25, 26, 36, 37, 71, 72 and 73 which refer to the plate
size, for further measurements, please see respective Product
Data Sheet on www.airec.com. The Compact family consist of sev-
eral types depending on material combinations, pressure ratings
and functions.
Principle sketch of Compact with Gas, Coolant and Condensate connections marked
Connections
All connections on the Compact are brazed in the general vac-
uum-brazing cycle, which gives a very strong seal between the
connection and the cover plates. However, do not use excessive
force which can damage the connection.
The Compact are available with connections adapted to the
model/size, for exact measurements, please see respective Prod-
uct Data Sheet on www.airec.com
.
The Compact are available with threaded ISO-G connections for
liquid and condensate connection. The gas connections are of
type welding/brazing connection.
Connection Types:
Gas Coolant Condensate
Compact
model
Gas
Connection
Coolant
Connection
Condensate
Connection
25
W 60 (DN 50)
G 0.75
G 0.25
26
W 60
G 0.75
G 0.25
36
W 85
(DN 80)
G 1
G 0.5
37
W 85
G 1
G 0.5
71
W 160
(DN 150)
G 2.5/W 70
G 1
72
W 160 G 2.5/W 70 G 1
73
W 110 (DN 100)
G 2.5/W 70
G 1
Connection configuration
The Compact heat exchangers are available in different connec-
tion configurations. There are four standard configurations: T, G,
O, and D.
Please note that other configurations than the ones pictured below
may exist.
T-connection G-connection
O-connection D-connection
Denomination / Product identification
All Airec heat exchangers are equipped with an adhesive label
which includes vital information about the unit, e.g. type of heat
exchanger, execution, material combination and item number.
The label also includes the serial number and Operating Condi-
tions; state the maximum operating material temperature and
pressure as per the respective approving organization. The label
confirms that the product has passed the pressure test.
Please note that additional documentation confirming that the
product has passed the pressure test demands a specification in
the order of the product.
❶ Compact 25-C-20-T
Product type: Compact
Size: 25
Brazing material: N (nickel) / C (copper)
Number of plates: 20
Connection configuration: T (all conn. on top-plate)
❷ Item number
❸ Serial number
❹ Operating conditions;
TS: Operating plate temperature min/room temperature
(max)
PS: Operating pressure min/room temperature (max)
PT: Test pressure
Volume: liquid side / gas side
Fluid group: according to approving organization
❺ Approving organization
❶
❷
❸
❹
❺
Coolant connection
Gas connection
Condensate connection
Pressure vessels
The product type Compact is manufactured according to the Euro-
pean Directive for Pressure Equipment (PED 2014/68/EU).
The pressure rating for the Compact is depending on the model
and type, please see respective Product Data Sheet on
www.airec.com
and/or contact Airec.
For copper brazed Compact the maximum operating wall temper-
ature is 220°C (428°F) and for nickel brazed the maximum operat-
ing wall temperature is 350°C (662°F).
Note: The gas temperature may be considerably higher than the ma-
terial temperature provided there is sufficient coolant temperature
and flow.
For divergent operating conditions, please contact Airec.
For approved units, the data on the label must not be exceeded at
any circumstances. The heat exchangers are designed for use
with fluids according to group 1 and 2 in AFS 2016:1.
For operating conditions concerning the European approval PED,
please see Product sheets on www.airec.com. For more details on
the respective approvals, please contact Airec.
Installation
Personal protection
Suitable protective clothing i.e. goggles, gloves and shoes shall be
worn whilst installing and/or maintenance of heat exchangers.
Please be aware of: - filled heat exchangers might be heavy, - heat
exchangers can be hot from high temperature operation, - con-
densate might be corrosive/caustic.
Connecting the Compact to the system
Compact can be installed in both vertical and horizontal direction.
Horizontal Vertical
Note! For condensing application, the installation is recommended to
be Vertical with Gas-flow from top – down through the heat ex-
changer, and condensation connection must be at lowest point to
avoid build-up of condensate inside the heat exchanger.
Flow direction of the fluids into the Compact heat exchanger can
be either:
Concurrent = fluids flow in the same direction through the heat
exchanger
or
Counter-current = that the fluids will move in the opposite direc-
tion through the heat exchanger.
Please consult the system drawings for the flow directions for the
Compact heat exchanger.
Countercurrent Concurrent
Mounting Compact
When mounting the Compact treat the heat exchanger with care
and do not use excessive force, bending or welding on the heat
exchanger.
Never expose the Compact heat exchanger to excessive pulsa-
tions (i.e. cyclic pressure or temperature changes). It is also
important that no vibrations are transferred to the unit. If there is
a risk of this, install vibration absorbers/muffler. For large connec-
tion diameters, we advise you to use an expanding device in the
pipeline. If installation allow it is also suggested that a buffer is
installed between the Compact and the support.
Regardless if the heat exchanger is mounted horizontal or vertical
the heat exchanger must have full support.
Do not install the Compact only to the connections as it will give
too high stress on the connections.
Airec suggest mounting according to below example. Support legs
and stud-bolts in different versions and locations are available as
option, please contact Airec.
Support from Bracket Stud-bolts Support legs
the bottom
Mounting stud bolts for BPHEs are available as an option. These
stud-bolts are welded to the BPHE. The maximum allowable loads
on the stud bolts during assembly are stated in below table.
Tension force
F
T
[N]
Torque moment
M
T
[Nm]
M6
1200
3,8
M8
2400
9,5
M10
3600
19
The maximum allowable connection loads given below are valid
for low cycle fatigue. If high cycle fatigue is involved special
analysis should be made. The following limits for moment should
not be exceeded.
Connection
Max. Traction
[N]
Max. Bending
Moment
[Nm]
Torque
Moment
[Nm]
Coolant
6000
50
150
Condensate
3000
20
70
Gas
6000
50
150
Welding/Soldering Connection and Pipe
When soldering; degrease and polish the surface. Apply flux, note
that flux properties make it potentially very aggressive and it is,
therefore, important to use the correct amount of flux, as too
much might lead to severe corrosion. No flux must be allowed to
enter the heat exchanger. Insert the copper tube into the
connection, hold it in place and braze with min. 45 % silver solder
at max. 450ºC (840ºF) when soft soldering and 450-800ºC (840-
1470 ºF) when hard soldering. Do not direct the flame at the
Compact. Use a wet rag to avoid overheating the Compact.
Protect the heat exchanger interior from oxidation with N
2
gas.
Excessive heating may cause serious damage to the heat
exchanger.
When welding; protect the heat exchanger from excessive heating
by using a wet cloth around the connection making a chamfer on
the joining tube and the connection edges. Use TIG or MIG/MAG
welding. If using electrical welding circuits, connect the ground
terminal to the joining tube, not to the back of the Compact. A
small flow of N
2
through the heat exchanger will reduce internal
oxidation.
Airec does not assume any responsibility for incorrect soldering
or welding nor for any accidents that may occur during the
process.
Operational conditions
The Compact is used with a liquid on the circuit with threaded
connections and a gas on the circuit with welding/soldering
connections. The heat exchanger must operate in line with
approved design parameters; temperatures, pressures and flow
rates.
Liquid side
Typical media are, Ethylene/Propylene glycol, Thermal oil, Water
or other for stainless steel non-corrosive coolant. It is important
that the coolant is of good quality without contamination or
corrosive substance. If any of the media contains particles larger
than 1 mm (0.04 inch), we recommend that a strainer with a size
of 16-20 mesh (number of openings per inch) is installed before the
Compact. The particles could otherwise block the channels,
causing bad performance, increased pressure drop and risk of
boiling.
System with water or another evaporating coolant must be
equipped with necessary bleeding valve mounted in a position
higher than the heat exchanger. Air/gas inside the liquid channels
will reduce heat transfer and the coolant circulation, which also
could cause boiling.
The liquid flow must be constant and with sufficient pressure to
keep its evaporating/boiling temperature above the plate
temperature. Local evaporation/boiling will adversely affect heat
transfer and water circulation and may lead to a risk of serious
damage to the heat exchanger. Note: The pressure at the coolant
outlet must be high enough to avoid boiling.
The Compact heat exchanger must always have the cooling fluid
circulating fully before the hot gas enters the heat exchanger.
The Coolant must NEVER be allowed to freeze.
Never expose the Compact heat exchanger to excessive liquid
pulsations (i.e. cyclic pressure or temperature changes).
Gas side
The gas media should not be corrosive to the heat exchanger.
Note: Copper brazed Compact products can under no circumstances
be used for gases containing NH
3
(Ammonia). The concentration of
sulphur and/or sulphur containing compound should be kept at a
minimum.
The gas flow must be started after, or simultaneously to, the start
of the liquid flow. If the liquid flow is interrupted, the gas must be
stopped or caused to by-pass the Compact heat exchanger to
avoid boiling on the liquid side.
The Compact heat exchanger must not be operated in such a
manner that stagnant condensate can accumulate. Never expose
the Compact heat exchanger to excessive gas pulsations (i.e. cyclic
pressure or temperature changes).
The heat exchanger can NEVER be operated without a coolant
flow.
Operation start-up
Make sure that:
- If there is a risk of high temperatures, the unit is insulated as
a precaution to avoid injuries.
- Installation has been carried out according to the flow
schedule/drawing and recommendations.
- Connections are tight.
- No vibrations or pulsations are transferred to the Compact
heat exchanger.
- The liquid side is filled and deaerated.
- The flow rate and pressure on the liquid side are correct
before gas flow is started.
- The temperature and flow rates are according to
specification.
- There is appropriate drainage to deal with any condensation.
Maintenance
The Compact has no moving parts or electrical components.
The following should be inspected regularly:
- Operational design conditions for the system being
maintained and meeting the calculated / design values
(leaving temp., pressure drop).
- Increased pressure drop and decreased thermal efficiency
over time are signs of possible fouling.
- Connections for tightness.
- Signs of corrosion.
- Seal and gaskets.
- External components such as valves, dampers and controls.
Cleaning
The normally high degree of turbulence in the Compact gives a
self-cleaning effect in the liquid channels, which reduces fouling
and the build-up of contamination, which can seriously reduce
heat transfer capacity and increase pressure drop.
Cleaning of Coolant side
In some applications, the fouling tendency can be very high, e.g.
when using extremely hard water at high temperatures. In such
cases, it is always possible to clean the Compact by:
- Circulating a cleaning liquid (CIP - Cleaning In Place).
- A solution of 5 % phosphoric acid or 5 % oxalic acid in water is
recommended to chemically clean the channels.
- The flow rate of the cleaning liquid should be greater than the
design coolant flow, and it should flow in the reverse
direction through the heat exchanger compared to the
normal operation flow direction.
- ATTENTION! After the cleaning process, it is very important that
the heat exchanger is flushed thoroughly with clean water before
start-up.
Cleaning of Gas side
Heavy condensation can have a self-cleaning effect, washing the
Compact and reducing fouling on the gas side. In applications
where the gas contains elements of soot, grease or oil residues
the risk of clogging the gas channel can be high. In such cases, it is
always possible to clean the Compact by:
- Blocking the gas connections.
- Circulating a cleaning liquid (CIP - Cleaning In Place) either
through the condensate connections or (if the fouling issue
have been addressed in the design phase) through specially
designed connections on the connecting pipes.
A suitable CIP-solution for the residues from the gas should
be used.
- ATTENTION! Chemicals known to corrode copper (i.e. ammonia,
sulphur, etc.) are strictly forbidden to use as cleaning agent.
- The flow rate of the cleaning liquid should be greater than the
design gas flow, and it should flow in the reverse direction
through the heat exchanger compared to the normal
operation flow direction.
- ATTENTION! After the cleaning process it is very important that
the heat exchanger is flushed thoroughly with clean water before
start-up.
Warranty
Airec offers a 12-month warranty from the date of installation, but
in no case longer than 18 months from the date of delivery. The
warranty covers only manufacturing and material defects (poor
workmanship and/or faulty material). The warranty does not
cover damage caused by mechanical (including fatigue damage
due to vibrations/pulsations) and/or thermal stress.
The warranty does not cover damage caused by corrosion.
The warranty does not cover damages caused by dirt build up
and/or fouling.
For further information please see www.airec.com
/support/down-
load.
Storage
The Compact shall always be stored in a dry and protective
environment. The temperature should not be below 1°C and not
over 50°C for long term storage (more than 4 weeks).
At long operational stand-by periods the system should be
inspected for contamination on Liquid and Gas side, if necessary
clean the Compact according to the cleaning instructions. Liquid
side with water should be drained.
Disclaimer
The Compact performance is based on installation, maintenance
and operating conditions done in conformance with this manual.
Airec cannot assume any liability for Compact heat exchangers
that do not meet these criteria.
Declaration of Conformity
It is hereby confirmed that the products Compact family has been
designed, manufactured, tested and documented to fulfil the
category requirements in the Pressure Equipment Directive
2014/68/EU, module B (production) + D (no. 15-1002306-100). The
products have been designed according to standard 13445.
Notified body: Inspecta 0409, PO Box 30100, SE-104 25 Stockholm,
Sweden.
Further information on the product identification label on
respective product.
AIREC AB
Signature:
Michael Bäärnhielm
For further information, please consult Airec’s technical information
or your local Airec representative.
AIREC AB
Hanögatan 5
SE-211 24 Malmö, Sweden
switch: +46 (0)40 93 63 60
www.airec.com
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Airec Compact 25 Installation and Maintenance Manual
- Type
- Installation and Maintenance Manual
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